Protective insert for commercial packaging of fragile stackable items

ABSTRACT

A one-piece protective insert comprising a plurality of laterally-aligned chambers each configured to fit a stack of fragile items, such as edible cones. Each chamber is formed by the union of a first sidewall, a second sidewall, a back wall and a top wall. A top flange and side flanges may be connected to the protective insert. In packaging multiple cone stacks, a protective insert is placed in between a first row of cone stacks and a second row of cone stacks, such that the top wall of each chamber of the protective insert is positioned above the open end of the cone stacks in the second row and each of the cone stacks in the second row fits within one of the chambers of the protective insert. This packing method is repeated for all successive rows of cone stacks within the container.

TECHNICAL FIELD

[0001] The present invention relates to packaging of fragile stackableitems, such as edible cones and the like. More particularly, the presentinvention relates to a protective insert for separating, supporting andprotecting fragile stackable items stacked within a container.

BACKGROUND OD THE INVENTION

[0002] As shown in FIGS. 1A-1C, large quantities of edible cones 102(e.g. 300 ct.) are typically packaged in a substantially rectangularcontainer 100 (e.g., a box) when sold for commercial use. Edible cones102 are placed within each other to form a cone stack 104. A pluralityof rows of cone stacks 104 are placed within the container 100. A coneholder 106 is typically used to hold the cone stacks 104 at spacedintervals. The cone holder 106 is often a piece of cardboard, paperboardor plastic supported a distance above the bottom of the container 100and having a number of openings 108 configured to receive the pointedends of the cone stacks 104.

[0003] With reference to FIGS. 2A-2C, in order to further support thecone stacks 104 within the container 100 and to protect the edible cones102 against breakage during transport, corrugated paperboard 200 istypically used as a protective insert. The corrugated paperboard 200 maybe folded so as to form multiple three-walled chambers 202, each havinga first side wall 204, a second side wall 206 and a back wall 208. Thesidewalls 204 & 206 of the chambers 202 may be positioned between thecone stacks 104 of a row of cone stacks 104 to ensure that the conestacks 104 do not touch each other. However, the three-walled chambers202 of the folded corrugated paperboard 200 do not cover the open end(i.e., the top) of the cone stacks 104 and therefore do not provide aprotective layer between the edible cones 102 and the top of the box100.

[0004] Folded corrugated paperboard 200 has been the protective insertof choice for packaging edible cones 102 because it is an inexpensivecommodity. However, in high-volume cone packaging facilities, the use offolded corrugated paperboard 200 as a packaging insert has drawbacks. Inparticular, the act of folding the corrugated paperboard 200 and holdingit in the proper three-walled configuration while inserting it betweencone stacks 104 is time consuming and thus limits the number ofcontainers 100 of edible cones 102 that can be packaged during a giventime period. In addition, constant repetition of the folding action hasbeen found to trigger carpel-tunnel syndrome in line-workers. Workerssuffering from carpel-tunnel syndrome may work more slowly, miss workmore often and possibly file workers compensation claims. Furthermore,corrugated paperboard 220 is not all that strong or shock-absorbent,which leads to more breakage of edible cones 102 than is necessary.

[0005] Accordingly, there remains a need for an improved protectiveinsert for use in bulk packaging of edible cones 102 for shipment tocommercial establishments. The improved protective insert should notrequire repetitive folding or assembly actions and should providesuperior protection against edible cone breakage.

SUMMARY OF THE INVENTION

[0006] The present invention meets the above-described need by providinga protective insert for use in packaging a plurality of fragilestackable items, such as edible cones. The protective insert comprises aplurality of laterally-aligned chambers that are configured to fit astack of edible cones. In one embodiment, each chamber is formed by theunion of a first sidewall, a second sidewall, a back wall and a topwall. The chambers are each configured to fit a stack of edible conesand may be substantially semi-cylindrical in shape. The protectiveinsert comprises a unitary construction that may be made from foam,plastic or any other suitable material.

[0007] In certain embodiments, a top flange may be connected to the topwall of the protective insert. The top flange may extend length-wise atleast partially along the length of the protective insert. The topflange may be connected to the front edge of the top walls and mayextend width-wise beyond the back edge of the top walls. The pluralityof chambers comprises a first end chamber, a second end chamber and aplurality of middle chambers positioned between the first end chamberand the second end chamber. A first side flange may be connected to thefirst side wall of the first end chamber and a second side flange may beconnected to the second side wall of the second end chamber.

[0008] Another aspect of the invention provides a method of packaging aplurality of cone stacks using the inventive protective inserts. Themethod comprises optionally placing a cone holder into a container nearthe bottom of the container. The cone holder is configured to receivethe pointed end of each of the cone stacks. A first row of cone stacksis placed into the container such that the pointed end of each conestack is received by the cone holder. A second row of edible cones isalso placed into the container such that the pointed end of each conestack in the second row is received by the cone holder. A protectiveinsert is placed in between the first row of cone stacks and the secondrow of cone stacks, such that the top wall of each chamber of theprotective insert is positioned above the open end of the cone stacks inthe second row and each of the cone stacks in the second row fits withinone of the chambers of the protective insert. This packing method isrepeated until all intended cone stacks and protective inserts areplaced within the container.

[0009] These and other aspects, features and embodiments of theinvention will become apparent from the following detailed descriptionof certain exemplary embodiments, the appended drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The invention is illustrated by the accompanying drawings inwhich like numerals represent like elements and in which:

[0011]FIG. 1A is a perspective view of an exemplary prior art package ofedible cones;

[0012]FIG. 1B is a sectional view of an exemplary prior art package ofedible cones;

[0013]FIG. 1C is a perspective view of an exemplary prior art coneholder typically used within a package of edible cones;

[0014]FIG. 2, comprising FIG. 2A, FIG. 2B and FIG. 2C, is anillustration of an exemplary piece of corrugated paperboard used as apackaging insert for packaging edible cones;

[0015]FIG. 3, comprising FIG. 3A, FIG. 3B and FIG. 3C, illustratesvarious view of an exemplary protective insert of the present invention;

[0016]FIG. 4, comprising FIG. 4A, FIG. 4B, FIG. 4C and FIG. 4D,illustrates an exemplary package for shipping edible cones in accordancewith the present invention; and

[0017]FIG. 5 illustrates an alternative embodiment of the presentinvention wherein two inventive protective inserts may be used tosurround a cone stack from all sides.

DETAILED DESCRIPTION EXEMPLARY EMBODIMENTS

[0018] The present invention provides an improved protective insert forbulk packaging of fragile stackable items for delivery to commercialestablishments. The protective insert of the present invention is aone-piece, pre-formed construction, meaning that no assembly orpreparation is required by the packager. The protective insert comprisesa plurality of laterally-aligned chambers that are designed to shieldmultiple sides, including the tops, of cone stacks 104 within acontainer 100. The protective insert may be made from a foam material(e.g., polystyrene, etc.), plastic or any other suitable material. Incertain embodiments the one-piece protective insert is formed using amolding process. For example, the one-piece protective insert may bemade from extruded material and thermo-formed using a mold.

[0019] Exemplary embodiments of the inventive protective insert will bedescribed herein with respect to packaging of edible cones 102, such asice cream cones. Those skilled in the art will appreciate, however, thatthe protective insert may be adapted for use in packaging other fragilestackable items, such as cups, bowls, novelty items, etc. As mentionedabove, FIGS. 1A-1C illustrate certain aspects of a typicalcommercial-grade package of edible cones 102. A number of edible cones102 are typically placed within each other to form a cone stack 104. Aplurality of rows of cone stacks 104 are placed within the container 100and are usually supported at spaced intervals by a cone holder 106. Thecone holder 106 may be a piece of cardboard, paperboard, plastic orother suitable lightweight material that is supported a distance abovethe bottom of the container 100 and has a number of openings 108configured to receive the pointed ends of the cone stacks 104.

[0020] An exemplary embodiment of the protective insert of the presentinvention is shown and described with reference to FIGS. 3A-3E. FIGS.3A-3B show a front, back and sectional view, respectively, of anexemplary protective insert 300. The protective insert 300 comprises aplurality of laterally-aligned chambers 302A-E. Each chamber 302A-E isformed by the union of multiple walls. In particular, a first chamber302A is formed by the union of a first sidewall 304A, a second sidewall306A, a back wall 308A and a top wall 310A; a second chamber 302B isformed by the union of a first sidewall 304B, a second sidewall 306B, aback wall 308A and a top wall 310B; a third chamber 302C is formed bythe union of a first sidewall 304C, a second sidewall 306C, a back wall308C and a top wall 310C; a fourth chamber 302D is formed by the unionof a first sidewall 304D, a second sidewall 306D, a back wall 308D and atop wall 310D; a fifth chamber 302E is formed by the union of a firstsidewall 304E, a second sidewall 306E, a back wall 308E and a top wall310E. As illustrated in FIG. 3A, the chambers 302A-E do not include abottom wall.

[0021] The chambers 302A-E of an exemplary inventive protective insert300 are described herein as having distinct chamber walls, i.e., eachchamber 302A-E has its own first sidewall 304A-E, its own secondsidewall 306A-E, its own back wall 308A-E, and its own top wall 310A-E.Those skilled in the art will appreciate, however, that the unitary(one-piece) construction of the protective insert 300 may mean thatcertain of such walls are distinct as a conceptual matter only. As apractical matter, for example, a single top wall 310 may extendsubstantially across all chambers 302A-E. In addition, adjacent chambers(e.g., 302A and 302B) may share a common sidewall (e.g., the second sidewall 306A of one chamber 302A may also serve as the first sidewall 304Bof another chamber 302B). Accordingly, any description of distinctchamber walls is meant only to clearly illustrate exemplary embodimentsof the present invention and is not intended to limit the scope thereof.

[0022] The chambers 302A-E are each configured to shield multiple sidesof a cone stack 104 and may thus have a cross-section that is similar inshape and size to that of an edible cone 102. In a preferred embodiment,the chambers 302A-E are substantially semi-cylindrical in shape (i.e.,semi-circular in cross-section) and have a diameter that is slightlylarger than that of a typical edible cone. Of course, the chambers302A-E may alternatively be formed to have a circular cross-section(resulting in a sleeve-like structure that encircles a cone stack 104),a semi-square or square crosssection, a semi-polygonal or polygonalcross-section, or any other shape cross-section. The overall protectiveinsert 300 is preferably substantially rectangular in shape, so as tofit neatly within a typical container 100 (e.g., a box), as shown in thesectional views of an edible cone package of FIGS. 3D-E. The dimensionsof the protective insert 300 may be varied to fit containers 100 ofvarying sizes. The inventive protective insert 300 may alternatively beformed into other any suitable shape to fit within any particularcontainer 100 configuration.

[0023] Each top wall 310A-E of each chamber 302A-E has a length and awidth. The length of each top wall 310A-E is substantially equal to alateral distance across the associated chamber 302A-E. The width of eachtop wall 310A-E is bounded by a front edge 312A-E (shown in FIG. 3A) anda back edge 314A-E (shown in FIG. 3B). Each back edge 314A-E is thelocation where a back wall 308A-E joins a top wall 310A-E.

[0024] In certain embodiments, a top flange 316 may be connected to thetop walls 310A-E of each chamber 302A-E. The top flange 316 may extendlength-wise at least partially along the length of the protective insert300. The top flange 316 may be connected to the front edges 312A-E ofeach top wall 310A-E and may extend widthwise, possibly beyond the backedges 314A-E of each top wall 310A-E. The top flange 316 mayalternatively be connected to the top wall 310A-E of each chamber 302A-Ein any other suitable manner. The plurality of chambers 302A-E comprisesa first end chamber 302A, a second end chamber 302E and a plurality ofmiddle chambers 302B-D. A first side flange 318A may be connected to thefirst side wall 304A of the first end chamber 302A and a second sideflange 318B may be connected to the second side wall 306E of the secondend chamber 302E. The side flange 316 may also extend widthwise,possibly beyond the back edges 314A-E of each top wall 310A-E. A lip 320may extend substantially perpendicularly from the top flange 316 and/orthe side flanges 318A&B. The lip 320, which may vary in size and shape,may help the protective insert to fit more snugly within a container100.

[0025] FIGS. 3D-E illustrate front and back sectional views,respectively, of an exemplary protective insert 300 positioned within acontainer 100 of edible cones 102. As shown, the protective insert 300is positioned within the container 100 so as to be behind (relativelyspeaking) a row of cone stacks 104. Each cone stack 104 in the row fitswithin one of the chambers 302A-E of the protective insert 300. The topflange 316 and side flanges 318A&B provide an additional layer ofshock-absorbent material between the container 100 and the edible cones102 and may also provide for a more snug fit within the container 100.

[0026] The exemplary protective inset 300 is shown as having a heightthat causes the bottom of the protective insert 300 to rest on or nearthe cone holder 106 within the container 100. Those skilled in the artwill appreciate, however, that it is not necessary for the protectiveinsert 300 to rest on or near the cone holder 106. The height of theprotective insert 300 may be such that at least some, if not most orall, of the edible cones 102 within a cone stack 104 are shielded by achamber 302A-E. As mentioned above, the dimensions of the protectiveinsert 300 may be varied depending on the size and configuration of thecontainer 100 (which may be dictated by the size and configuration ofthe cone stacks 104.) It may be desirable to minimize the height of theprotective insert 300 in order to reduce the material costs and shippingweight.

[0027] FIGS. 4A-D illustrate an exemplary package 400 for shippingedible cones 102 in accordance with the present invention. The exemplarypackage 400 comprises the container 100 having disposed therein a numberof rows of cone stacks 104. Each cone stack 104 has a pointed end (i.e.,bottom) and an open end (i.e., top). The cone stacks 104 may besupported at spaced intervals by a cone holder 106. A protective insert300 of the present invention is inserted behind (relatively speaking)each row of cone stacks 104. With such an arrangement, a protectiveinsert 300 is positioned between each successive row of cone stacks 104.The chambers 302A-E of each protective insert 300 shield a row of conestacks 104 from behind, on each side and from the top. The front side ofa row of cone stacks 104 is protected by the back wall 308 (andoptionally by the top flange 316 and side flanges 318A&B) of theprotective insert 300 that is positioned in front of that row of conestacks 104 (i.e., the protective insert that is positioned behind thenext successive row of cone stacks 104).

[0028] According to another aspect of the invention, a method ofpackaging edible cones 102 using the inventive protective inserts 300 isprovided. The method optionally comprises placing a cone holder 106 intoa container 100 near the bottom of the container 100. The cone holder106 may be configured to receive the pointed end of each of the conestacks 104 that are to be placed in the container 100. A first row ofcone stacks 104 is placed into the container 100 such that the pointedend of each cone stack 104 is received by the cone holder 106. A secondrow of cone stacks 104 is also placed into the container 100 such thatthe pointed end of each cone stack 104 in the second row is received bythe cone holder. This process is repeated until the container is filledwith the desired number of rows of cone stacks 104.

[0029] A protective insert 300 may then be placed in between the firstrow of cone stacks 104 and the second row of cone stacks 104, such thatthe top wall 310A-E of each chamber 302A-E of the protective insert 300is positioned above the open end of the cone stacks 104 in the secondrow and each of the cone stacks 104 in the second row fits within one ofthe chambers 302A-E of the protective insert 300. The first row ofedible cones 104 may be substantially near a side of the container 100and a second protective insert 300 may be placed between the side of thecontainer 100 and the first row of cones 104, such that the top wall310A-E of each chamber 302A-E of the second protective insert 300 ispositioned above the open end of the cone stacks 104 in the first rowand each of the cone stacks 104 in the first row fits within one of thechambers 302A-E of the second protective insert 300. In a like fashion,additional protective inserts 300 may be placed between each twosuccessive rows of cone stacks 104.

[0030] Cone stacks 104 may be placed into the container 100 by anautomated packing machine. As each row of cone stacks 104 is placed intothe container 100, a line-worker may manually insert a protective insert300 into the container 100 behind the row of cone stacks 104.Alternatively, the line-worker may wait until all rows of cone stacks104 are placed within the container 100 before inserting the protectiveinserts 300.

[0031] In an alternative embodiment, shown by way of example in FIG. 5,two protective inserts 300 of the present invention may be used tosurround a cone stack 104 from all sides. The two protective inserts 300may be positioned on opposite sides of the cone stack 104, each havingits chambers 302 facing each other. This configuration create asleeve-like structure that surrounds the cone stack 104. As mentionedpreviously, such an alternative configuration may be accomplished usingone protective insert 300 that is designed with chambers 302A-E havingfor example a circular crosssection, as opposed to two protectiveinserts 300 each designed with chambers 302A-E having a semi-circularcross-section.

[0032] Although the present invention has been described with referenceto certain exemplary embodiments thereof, those skilled in the art willrecognize that changes may be made thereto in form and detail withoutdeparting from the spirit and scope of the invention. Features andaspects of the present invention have been described and/or depicted byway of example only and are therefore not intended to be interpreted asrequired or essential elements of the invention. The specificembodiments described herein are thus given by way of example only. Theinvention is to be limited only as defined by the following claims.

What is claimed is:
 1. A protective insert for use in packaging aplurality of edible cones comprising: a plurality of laterally-alignedchambers each formed by a union of a first sidewall, a second sidewalland a back wall, each chamber configured to fit a stack of edible cones;a top wall extending at least partially over each of the plurality ofchambers; and wherein the plurality of chambers and the top wallcomprise a unitary construction.
 2. The protective insert of claim 1,wherein the top wall has a length and a width, the length beingsubstantially equal to a lateral distance across the plurality ofchambers; and wherein the protective insert further comprises a topflange connected to the top wall and extending length-wise at leastpartially along the length of the top wall.
 3. The protective insert ofclaim 2, wherein the width of the top wall is bounded by a front edgeand a back edge, the back edge being a location where the back wall ofeach chamber the joins the top wall; and wherein the top flange isconnected to the front edge of the top wall and extends width-wisebeyond the back edge of the top wall.
 4. The protective insert of claim2, wherein the plurality of chambers comprises a first end chamber, asecond end chamber and a plurality of middle chambers positioned betweenthe first end chamber and the second end chamber; and wherein theprotective insert further comprises a first side flange connected to thefirst side wall of the first end chamber and a second side flangeconnected to the second side wall of the second end chamber.
 5. Theprotective insert of claim 1, wherein the plurality of chamberscomprises a first end chamber, a second end chamber and a plurality ofmiddle chambers positioned between the first end chamber and the secondend chamber; and wherein the protective insert further comprises a firstside flange connected to the first side wall of the first end chamberand a second side flange connected to the second side wall of the secondend chamber.
 6. The protective insert of claim 1, wherein the unitaryconstruction is made from foam.
 7. The protective insert of claim 1,wherein the unitary construction is made from plastic.
 8. The protectiveinsert of claim 1, wherein the unitary construction is formed using amolding process.
 9. The protective insert of claim 1, wherein each ofthe plurality of chambers is substantially semi-cylindrical in shape.10. The protective insert of claim 1, wherein the plurality of chamberscomprises five chambers.
 11. A protective insert for use in packaging aplurality of edible cones comprising: a plurality of laterally-alignedchambers each formed by a union of a first sidewall, a second sidewall,a back wall and a top wall, each chamber configured to fit a stack ofedible cones; a top flange extending at least partially over each topwall of the plurality of chambers; and wherein the plurality of chambersand the top flange comprise a unitary construction.
 12. The protectiveinsert of claim 11, wherein each top wall has a width that is bounded bya front edge and a back edge, the back edge being a location where theback wall joins the top wall; and wherein the top flange is connected tothe front edge of each top wall and extends width-wise beyond the backedge of each top wall.
 13. The protective insert of claim 12, whereinthe plurality of chambers comprises a first end chamber, a second endchamber and a plurality of middle chambers positioned between the firstend chamber and the second end chamber; and wherein the protectiveinsert further comprises a first side flange connected to the firstsidewall of the first end chamber and a second side flange connected tothe second sidewall of the second end chamber.
 14. The protective insertof claim 11, wherein the plurality of chambers comprises a first endchamber, a second end chamber and a plurality of middle chamberspositioned between the first end chamber and the second end chamber; andwherein the protective insert further comprises a first side flangeconnected to the first side wall of the first end chamber and a secondside flange connected to the second side wall of the second end chamber.15. The protective insert of claim 11, wherein the unitary constructionis made from foam.
 16. The protective insert of claim 11, wherein theunitary construction is made from plastic.
 17. The protective insert ofclaim 11, wherein the unitary construction is formed using a moldingprocess.
 18. The protective insert of claim 11, wherein each of theplurality of chambers is substantially semi-cylindrical in shape. 19.The protective insert of claim 11, wherein the plurality of chamberscomprises five chambers.
 20. A method of packaging a plurality of conestacks using protective inserts, each protective insert comprising aplurality of laterally-aligned chambers each formed by a union of afirst sidewall, a second sidewall, a back wall and a top wall, eachchamber configured to fit an cone stack, each cone stack having apointed end and an open end, the method comprising: placing a coneholder into a container having a bottom and a top, the cone holder beingplaced near the bottom of the container and being configured to receivethe pointed end of each of the plurality of cone stacks; placing a firstrow of cone stacks into the container such that the pointed end of eachcone stack in the first row is received by the cone holder; placing asecond row of edible cones into the container such that the pointed endof each cone stack in the second row is received by the cone holder; andplacing a protective insert between the first row of cone stacks and thesecond row of cone stacks, such that the top wall of each chamber of theprotective insert is positioned above the open end of the cone stacks inthe second row and each of the cone stacks in the second row fits withinone of the chambers of the protective insert.
 21. The method of claim20, wherein the first row of cones is substantially near a side of thebox; and wherein the method further comprises placing a secondprotective insert between the side of the container and the first row ofcones, such that the top wall of each chamber of the second protectiveinsert is positioned above the open end of the cone stacks in the firstrow and each of the cone stacks in the first row fits within one of thechambers of the second protective insert.
 22. The method of claim 20,wherein the protective insert is made from foam.
 23. The method of claim20, wherein the protective insert is made from plastic.
 24. The methodof claim 20, wherein each of the chambers of the protective insert issubstantially semi-cylindrical in shape.
 25. The method of claim 20,wherein the protective insert further comprises a top flange extendingat least partially over each top wall of the plurality of chambers;wherein each top wall of the plurality of chambers has a width that isbounded by a front edge and a back edge, the back edge being a locationwhere the back wall joins the top wall; wherein the top flange isconnected to the front edge of each top wall and extends width-wisebeyond the back edge of each top wall; and wherein the protective insertis placed in the container such that the top flange extends at leastpartially above the first row of cones.
 26. A package of edible conescomprising: a container; a plurality of rows of cone stacks disposedwithin the container, each cone stack having a pointed end and an openend; and a plurality of protective inserts disposed within thecontainer, each protective insert comprising a plurality oflaterally-aligned chambers each formed by a union of a first sidewall, asecond sidewall, a back wall and a top wall, each protective insertpositioned behind one of the rows of cone stacks such that each of thecone stacks fits within one of the chambers of the protective insert.27. The package of edible cones recited in claim 26, wherein theprotective insert further comprises a top flange extending at leastpartially over each top wall of the plurality of chambers.
 28. Thepackage of edible cones recited in claim 27, wherein each top wall ofthe plurality of chambers has a width that is bounded by a front edgeand a back edge, the back edge being a location where the back walljoins the top wall; wherein the top flange is connected to the frontedge of each top wall and extends width-wise beyond the back edge ofeach top wall; and wherein the protective insert is positioned such thatthe top flange extends at least partially above the row of cones. 29.The package of edible cones recited in claim 26, wherein the pluralityof chambers comprises a first end chamber, a second end chamber and aplurality of middle chambers positioned between the first end chamberand the second end chamber; and wherein the protective insert furthercomprises a first side flange connected to the first side wall of thefirst end chamber and a second side flange connected to the second sidewall of the second end chamber.
 30. The package of edible cones recitedin claim 26, wherein the protective insert is made from foam.
 32. Thepackage of edible cones recited in claim 26, wherein the protectiveinsert is made from plastic.
 33. The package of edible cones recited inclaim 26, wherein the protective insert is formed using a moldingprocess.
 34. The package of edible cones recited in claim 26, whereineach of the plurality of chambers is substantially semi-cylindrical inshape.